Synthetic graphite is created through a series of intricate processes that convert raw materials into a highly ordered carbon structure.
7 Key Steps Explained
1. Raw Material Preparation
The primary raw materials used are coke and graphite. These materials are milled and then mixed with binder pitch to form a homogeneous mass. This mixture is essential for the initial shaping of the graphite.
2. Shaping
The mixture is shaped using methods such as isostatic pressing, extrusion, vibration molding, or die molding. These processes determine the initial form of the graphite, often referred to as "green" material.
3. Carbonization
The shaped "green" material is subjected to an oxygen-free environment where it is heated to about 1000°C. This process forms binder bridges between the solid particles, stabilizing the structure.
4. Graphitization
Following carbonization, the material undergoes graphitization. This involves heating it to roughly 3000°C. This high-temperature treatment transforms the amorphous carbon into a highly ordered 3-D graphite structure.
5. Secondary Pulverizing
After the initial shaping, the formed small carbon balls are milled again to achieve very fine grains. This is essential for the uniformity and quality of the final product.
6. Isostatic Pressing
The fine grains are then subjected to high pressure (over 150 MPa) in large molds. This process ensures that the graphite grains are symmetrically arranged and evenly distributed, leading to consistent properties throughout the graphite block.
7. Machining and Purification
Once the graphite is fully formed, it undergoes machining to meet specific customer requirements. For applications requiring high purity, such as in the semiconductor industry, the graphite is purified using chemical methods, typically involving treatment with halogen gases at high temperatures.
8. Surface Treatment and Shipment
Depending on the application, the graphite surfaces may be further treated for smoothness or other desired characteristics. After final inspection, the finished graphite products are packed and shipped to customers.
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